HELP! Engine rebuild complete but clutch isn't working-FIXED

Hi,
Please can someone shed some light on where to look next?
I sourced another XJ650 engine for my bike (after my other one having the starter clutch chain guide failure and finding more problems).
Engine has been totally rebuilt but when after i re-connected the clutch cable assembly and put her into gear...CLUNK....it was quite apparent that the clutch wasn't working. I removed the casing and took out all the clutch friction plates and metal plates as shown in the manual (they weren't all jammed together as i thought they may be (as the guy i bought the engine off put the clutch together and it was sat for a while, months i think).
I have adjusted and seemed to have tried everything but if i pull the clutch in as full as it'll go put her into gear (without the engine running) and try to push her it's still as if i haven't even pulled the clutch in.....she won't even move. It's seems the clutch just doesn't work?
I've looked in the service manual and on the XJCD but i'm beat!
The only thing i haven't checked is the clutch spring lengths (says they should be 39.1mm) - if they are knackered could that be the probem?
Thanks
Nick

 

Re: HELP! Engine rebuild complete but clutch isn't working

could be have you set the post comeing from the clutch plate in the correct poision? i know bad spelling it's what i learned in skool

 

Re: HELP! Engine rebuild complete but clutch isn't working

Anyone got any more ideas please.....it's done me in!
I cleaned all the plates (they weren't stuck) i adjusted the clutch rod and made sure there was no excessive play. It's adjusted right up tight everywhere BUT...as soon as i put her into gear it jumps forward and dies!
I've measured the springs (all fine) as per the manual
I've measured the friction plates (look new and oiled)
Also the metal plates in between are all clean and not warped.
If i put her in gear (with engine off) pull in clutch she won't freewheel. You should be able to do that right.
I've taken the clutch apart 3 times and i just can't see what's wrong?
Please help before the bad weather comes back.
Thanks..Nick

 

Re: HELP! Engine rebuild complete but clutch isn't working-F

Ok here goes,,, it turns out that the Previous owner had incorrectly installed the clutch in the first place (and i was a dummy in not checking it) but hey, that's how we learn right!
Anyway, as i said before i completely removed the clutch and re-installed as per the manual.
However, what i failed to do was make sure the the lugs on the back of the clutch boss assembly no.7 on this page was engaged with no.6 and it wasn't seated properly.
This had the result in the clutch boss assembly not spinning!
(Which i failed to notice) so each time i put it back together i tightened the boss nut and didn't realize that the whole assembly in the middle should rotate freely.
Now i feel a bit of a dummy, but i've never done the clutch before.
Since the engine rebuild and the clutch work and with the help and knowledge on this site i really feel i know my bike so much better.
I'll be taking her (and the wife) out tomorrow night wooo hooo back on the road again!
P.S. while it was 'out of action' i have resprayed the tank, fitted some highway pegs, cleaned her up and greased and oiled everything with duck oil.
.

 

cool man glad you got it squared away

 

Re: HELP! Engine rebuild complete but clutch isn't working-F

Excuse me for asking what might sound like a stupid question, but... 'duck oil'?

 

Re: HELP! Engine rebuild complete but clutch isn't working-F

Yes, i was recommended it by a bike mechanic who said that it's totally the best stuff for lubricating cable innards as it doesn't go 'gummy' and can be used on cables that have nylon inners.
It's made by Swarfega